Week 1:- Introduction to BiW and Fixtures Challenge

Aim :  1) Initiate a concept of fixture design with reference to all inputs provided for the car panel. 2) Complete 3D finish work. 3) Complete 2D finish with output documentation. 4) Write a detailed report describing the process and attach relevant images.   Report :  1) Fixture concept design : …

Aim : To create a BOM and Hardware list (BOP) for the complete fixture assembly from challenge 8. Theory :  Bill of materials : A bill of materials is a comprehensive inventory of raw materials, assemblies, subassemblies, parts and components as well as quantities of each, needed to manufacture a product. Bill of…

Aim: 1. To create 2D drawing for each clamp units with all child parts and create child part drawing for the same for the fixture assembly created in challenge 8. 2. To create 2D drawing for each pin units with all child parts and also create child part drawing for the same for fixture assembly created in challenge 8.…

Objective :  1. To draft a key sheet for the complete fixture assembly created in challenge 8. 2. To draft a base unit and the fix pin unit drawings with all child parts for the complete fixture assembly from challenge 8.   Report : Key sheet  of the complete fixture assembly Keysheet is an index unit and…

1) What are drawing templates ?  Drawing templates are the files of frames and title block which convey the design information that are used to generate 2D drawing from 3D part.  Neat and detailed drawing template convey more information from designer to manufacturer. So we can avoid misunderstanding and make…

Aim : To perform 3D finish and create rough locators for the assembly design.   3D FINISHING :  3D finishing is a process where the design is being completely finished and ready for final simulation and 2D detailing. While finishing the design the nominality is checked which ensures the easy assembly of all the…

1. What do you understand by the 3D finish process ? 3D finishing is the process where the design is completely finished and to be ready for final simulation and 2D detailing. Steps followed in 3D finish are : The gaps between the different units are checked to ensure the proper individual working of different units. The…

Aim : To design a base unit for the pin units, clamp units, rest units and other units with all weldments for the given car panel. Theory: 1.Base Unit :  A Base unit is a unit designed to mount all other units (Clamp unit, Pin unit, Rest unit etc.) of the tool, also other parts necessary for a tool like pneumatic…

Q1. What is Base unit? What are the typical parts of the base unit?  A Base unit is the unit designed to mount all the other units (Clamp unit, Pin unit, Rest unit etc.,) of the tool, also other parts necessary for a tool like pneumatic valve box, trunking cable path will be also be mounted on to a base unit. Below…

Aim : To design 3 different types of swivel clamp unit with different riser, blade and clamp arm of the given car panel and design a pin clamp unit for the given car panel. Introduction :  Swivel clamp unit :  A swivel clamp unit is a unit designed to clamp/hold the car panel with NC blocks / rests / mylars by…

Aim : Route the wiring harness on given car body and prepare flatten view drawing in CATIA V5. Objective : The objective is to route the wiring harness and prepare flatten drawing view for the tailgate of the car applying all packaging rules and industry best practices. Apply protection coverings and consider the clearance…

Aim : Route the wiring harness on given V-16 engine and prepare flatten view in CATIA. Apply all packaging rules and industry best practices. Theory : The given V-16 engine consist of following electrical components to which harness routing is required. 8+8 fuel injectors on the engine cylinders for both sides of the engine…

Aim : To flatten the harness assembly of the wiring harness layout and place the flattened view on drawing sheet. Images : Harness assembly  Procedure :  1. Create a new product file and switch to electrical harness flattening workbench and save the file in the same folder where the harness assembly layout is…

Aim :  To route the following harness layout in Electrical workbench and  1. Check the bundle continuity. 2. Add annotation to all connectors. 3. Check for the bundle warning. 4. Generate CAT.part of harness assembly and convert it in .igs format. Procedure : 1. First provide the necessary properties to all the…

Aim :  To route the following harness layout in electrical workbench and add protective coverings on all branches connected to DT06-2S & DT06-4S with end extremities 30mm away from connectors end Procedure :  The wiring harness product assembly consists of  Context assembly (which conatins the surrounding…

 Aim :  To define given P clamp CAD data as an electrical support using electrical part design workbench & define all the necessary properties. to define given Backshell CAD data as an electrical backshell using electrical part design workbench & define all the necessary properties. To create COT tubes…

Aim : To define connectors & connector clip data  as Electrical Connector using Electrical Part design workbench & define all necessary properties to connectors & clip. Procedure :  a) Creating Connectors connections 1) Open the connector in part design 2) Define Harness bundle point at the entry…

Aim : To design 3 different types of power clamp unit and 2 different types of rest unit using different riser, blade and clamp arm for the given car panel. Introduction :  Clamp unit : A clamp unit is a unit designed to clamp / hold the car panel with NC blocks / rests / mylars by using a pneumatic clamp cylinder.…

Objective : To design 2 different types of fix pin unit and retractable pin unit. Introduction :  Pin unit is a unit designed to locate a car panel using pins. It is necessary to have 2 pin units to locate a car panel. And here one pin must arrest 4 way (4 translational) and other must arrest 2 way and other…

1.What is design methodolgy ? Image shows steps in Design methodolgy 1. Purchase order : Purchase order is the order from the customer for start of work.   2. Inputs from customer : For BIW fixture designing the customer demands some requirements to be fulfilled in it viz., functional requirements, preferred…

1. What is the process of project execution activity? Project activities for a BIW assembly refers to the activities carried out within an organisation, from the start, when a project is received from the customer till when a project is fully finished with customer approval for the fixture.  Image : BIW assembly project…

1. What is BIW and define its parts? Body in White (BIW) refers to the welded sheet metal components which forms the vehicle structure to which the other components will be married i.e., engine, chassis, exterior and interior trim.  BIW refers to the stage in automotive design or automobile manufacturing in which…

Car back door is the door at the rear end used to provide access to storage compartment of the car or also in few car cases to the rear seats of the car.  Car back door assembly consists of several main parts namely; 1. Inner panel 2. Outer panel upper 3. Outer panel lower 4. Hinge reinforcement  5. Gas stay…

A roof is the portion of an automobile that sits above the passenger compartment, protecting the vehicle occupants from the sun, wind, rain and other external elements. The roof assembly consist mainly of roof, front roof rail, bow roof rails and rear roof rail. 1. Roof : Roof is the main part of the roof assembly. The…

Section modulus is a geometric property for a given cross section used in the design of beam or flexural members. Section modulus (S) is given by formula, S =I/y where I is the moment of inertia and y is the distance from the neutral axis to the most extreme fiber. Section modulus is often used to determine yield moment(My)…

Fender is a part of automobile that frames a wheel well. Its primary purpose is to prevent sand, mud, rocks and other particles on the road being thrown into the air by the rotating tyre.    There are 2 types of fender designs 1. Half bumper type 2. Full bumper type Half bumper type fender are usually prefered…

The hood of a car is a metallic cover which covers the engine and also allows access to the engine for repair and maintainence. The overall hood assembly consist of hood outer panel, hood inner panel, hinges and striker.   1.Hood outer panel : Hood outer panel is the outer sheet metal cover which provides aesthetics to…

Underbody coating is usually a dense cladding applied uniformly to the undercarriage of the automobile. it is normally sprayed or painted on when the car is just out of the dealership. The main purpose of underbody coating is to prevent corrosion and rusting in the body components like frame rails along with other exposed…

Benchmarking involves a structured comparison between similar products, services or processes on some dimensions of performances. Benchmarking provides recommendation based on which is best or some form of ranking amongst competitors for the desired product or services.It can be used to compare the availabilty and delivery…

1. Title of the project : Metal bracket 2 2. Objective : To create metal bracket from the given 2 D drawing. 3. Introduction : Firstly set the sheet metal preferences and the procedure to design is carried out thereafter. 4. Objective :  1. Sketch the required 2D drawing on YZ plane as required as shown in the front…

1. Title of the project : Bracket Design 2. Objective : To create bracket from given 2D drawing. 3. Introduction : To begin with first the sheet metal preferences are set and then the design steps are performed succeedingly. 4. Description :  1. Draw a sketch of a suitable profile and go to counter flange command…

1. Title of the project : Odd shaped enclosures 2. Objective : To design sheet metal part for odd enclosures using NX sheet metal application. 3. Intoduction : A solid body is created using modelling application and converted to sheet metal and additionally a few sheet metal features are added to the obtained required…

Title of project : Box Assembly design Objective: To design the Box assembly using NX CAD software. Introduction : To begin the design proced ure  first the global parameters of Sheet metal are to be set and then box assembly is designed as per the guidelines  Description :  1. Select tab command and draw a rectangle on…

Title of the project : Casing Design Objective : Design a sheet metal casing using NX sheet metal applcation Introduction : To start designing in NX CAD, we first set all the global parameters : material thickness, bend radius, relief depth, relief width to 1mm and henceforth the  sheetmetal parameters are set to 1mm as…